High-Precision Yarn Break Detection | Minimize Fabric Defects | Reduce Labor Dependence

Overview: Next-Level Fabric Quality Assurance

In warp knitting, even a single broken yarn can compromise fabric integrity—leading to costly rework, material waste, and brand reputation risk. That’s why GrandStar’s Laser Stop System was engineered: to provide real-time, laser-accurate yarn break detection, delivering the highest standard of quality control in modern textile production.

Designed to meet growing industry demand for precision automation, the system integrates seamlessly with a wide range of warp knitting equipment—especially Tricot and Warping Machines—to halt production instantly upon detecting yarn breaks. The result: flawless fabrics, reduced labor cost, and optimal machine uptime.

How It Works: Smart Laser-Based Yarn Monitoring

At the heart of the system lies a high-sensitivity laser emitter-receiver pair. Operating on laser and infrared light principles, the system continuously scans yarn movement across 1 to 8 monitoring points per module. If any yarn crosses—or fails to cross—the beam due to a breakage, the system instantly recognizes the anomaly and sends a stop signal to the knitting machine.

This intelligent detection minimizes the likelihood of defect propagation. Rather than allowing the machine to continue operating with a damaged warp yarn, the Laser Stop immediately halts the machine, protecting both fabric quality and machine longevity.

Key Features & Technical Advantages

• Multi-Head Monitoring: Configurable from 1 to 8 heads per module for flexible setups across fabric widths and yarn densities.
• High Detection Sensitivity: Laser and infrared beam integration ensures reliable detection at high speeds and in low-light conditions.
• Instant Stop Response: Ultra-low system latency prevents unnecessary defect production.
• Wide Compatibility: Easily integrated into Tricot Machines, Warping Machines, and legacy systems.
• Cost-Effective & Labor-Saving: Reduces manual inspection efforts and supports lean manufacturing.
• Compact & Durable Design: Engineered for textile environments with heat, dust, and vibration resistance.

Competitive Edge: Why Choose GrandStar Laser Stop?

Compared to traditional mechanical tension detectors or ultrasonic systems, GrandStar’s Laser Stop offers:

• Superior Accuracy: Laser and infrared technology outperform older detection methods.
• Fewer False Positives: Advanced filtering reduces errors caused by ambient vibration or lighting shifts.
• Easy Integration: Plug-and-play design ensures smooth compatibility with existing electrical cabinets.
• Proven Reliability: Widely tested across global production floors with minimal recalibration needs.

Applications Across the Warp Knitting Industry

The Laser Stop system is trusted in various applications:

• Tricot Machines: Especially valuable in high-speed, fine fabric operations where yarn breaks cause visible defects.
• Warping Machines: Ensures quality consistency during yarn preparation.
• Retrofit Projects: Ideal for upgrading second-hand or legacy warp knitting systems.

From lace and sportswear to automotive mesh and industrial textiles, quality starts with detection—and Laser Stop delivers.

Unlock Zero-Defect Production with GrandStar

Ready to elevate your quality control standards? GrandStar’s Laser Stop System empowers you to scale production confidently while maintaining zero-defect standards.

Q: How many laser heads are required for yarn break detection on a warp knitting machine?

A: The number of laser heads required depends directly on how many yarn positions need to be monitored for breakage during operation.

Single Yarn Path Monitoring:

If each yarn passes through only one detection point, then one set of laser heads is sufficient for that position.

Multiple Yarn Path Monitoring:

If the same yarn passes through two or more distinct positions where breakage needs to be detected, then each position requires its own dedicated laser head set.

General Rule:

The greater the number of critical yarn positions, the more laser head sets are required to ensure reliable and accurate monitoring.

This modular approach allows manufacturers to customize the yarn break detection system based on the machine’s configuration, fabric structure, and production quality standards. Accurate laser-based monitoring helps minimize downtime, reduce fabric defects, and maintain consistent product quality—especially in high-speed production of technical or fine-gauge fabrics.